Apparatus for and method of sewing plaits



June 10, 1941. A. H. HABERSTUMP 2.244.691

APPARATUS FOR AND IETHOD 0F SEWING PLAIIT'S Filed July 23, 1937 5Sheets-Sheet 1 June 1D, 1941. A. H. HABERSTUMP l 2,244,591

APPARATUS FOR AND METHOD OF SEWING PLAITS Filed July 25, 1937 5.sheets-sheet 2 M2@ Miam A Trax/v5 ys'.

- June 10, 1941. A. H. HABERSTUMP APPARATUS FOR AND METHOD OF SEWINGPLAITS 5 Sheets-Sheet 3 /N VENTOR Hderfamp Filed July 23, 1937 HZff'cJ/BY f A TTORNEY?.

June 10, 1941- A. H.,.HABERsTuMP 2,244,591

APPARATUS FOR AND METHOD OF SEWING PLAITS Filed July 25, 1937 v ssheets-sheet 4 A TTOR NE ra.

June 10, 1941. A. H. HABERSTUMP 2,244,691

APPARATUS FOR AND METHOD OF SEWING PLAITS Filed July 23, 1937 5Sheets-Sheet 5 A TTORNE Ys.

Patented June 10, 1941 -umTED4 STATES PATENT OFFICE A'PIARATUS FORAllrnllsTIHOD OF SEWING Alfred H; Haberstump, Detroit, Mich., assignortoThe Murray Corporation of America, Detroit, Mich.,a corporation ofDelaware Application July 23, 1937, Serial No. 155,281

My invention relates to automatic means for stitching upholsterymaterial, and particularly to a methodgand system for combining a.backing element, `apad, and trim material by multiple stitching'ofplaits therein,

Multi-plaiting -machines have been employed heretofore for sewing plaitsin upholstery pads combining a backing element, paddingmaterial and atop trim material. been devised to obtain plait fullness in the covermaterial before stitchingL this being accomplished before thel materiallis ldisposed upon 4the pad.

After the -plait fullness was obtained in the material, it was eitherdisposed on the pad for sewing or, on the backing element before orafter thetime a bat was being inserted in each of the plaits formed inthis manner. The two materials were sometimes sewed together along theplait lines andthe paddingmaterial was pushed, blown, or otherwiseforced into the pockets formed thereby.

In practicing my present invention, I materially simplify the method ofsewing pads by employing a plurality of sewing heads disposed in lateralalignment and direct the `backing element, pad, and cover materialthrough the machine to sew the materials in the same manner as any otherthree` materials would be sewed together.

I, however, employ a unique system for forming and assembling thematerials and uniting them for sewing. A backing cloth is fed uponthe'conveyorof a garnetting" machine, which distributes layers oflinters on the backing cloth which, upon reaching proper thickness iscarried progressively through rolls to be compressed. The material isthen advanced on a, belt which is periodically operated to move the endof the material into a press. The press is provided with a die whichstamps the pad and backing material to a predetermined size and form.The formed material is then advanced to a position to receive the toptrimmaterial which has been cut to the desired formand which is providedwith pleat fullness' through the operation of pivotal arms which'simultaneously move into contact with the cloth to gather vmaterialaiongthe lines to be sewed. Thereafter the material is moved onto acontinuously operating conveyor chain which advances `the assemblythrough the machine where it is` sewed along thelines on which the`gathering occurred. f A. y o

Accordingly. the main objects of my invention are to provide a machineior compressing a backing sheet, a pad and trim material along lineswhich forms pleats during the time stitching oc- Methods have also4 1,6claims. (ci. Y11a-ez) curs along said lines; to Y continuously feedabacking sheet and a pad to a press whieh-simul,

taneously 'stamps out the sheet and material to f predetermined size and`form and delivers lsaid material from the machine to advance abaci-ringA sheet and pad which are stamped to a predetermined form to aposition to receive a sheet' of trim material and thereafter advancingthe assembled elements to a position above a conveyor chain; to lowerthe assembled elements upon the conveyor chains after it is advanced toa position thereabove; to garnett layers of linters upon a backing sheetas it is progressively advancedl to form a pad thereon, which pad andbacking element is 'advanced toa press which stamps out sections ofpredetermined size and shape; to'advance sections of padding and .sheetvmaterial of predetermined size and shape and to place sheets of covermaterial thereon and to, provide ,pleat fullness toV the cover materialafter-A it is located on the sections, and', in general, to provide apad and a method for its construction which is simple, positiveandeconomical of manufacture.

Other objects and features of novelty of my invention will bespecifically pointed out or will becomeapparent when referring, `for abetter understanding of my invention, to the following description takenin conjunction with th'e accompanying drawings, wherein: i

Figure 1 is a view in perspective of aseries of machines andoperatingdevices which the method of my invention;

Fig. 2 is a view of the pads which are constructed on the deviceillustrated in Fig. 1,-when mounted on a seat and back frame;

Fig. 3 discloses the'various operations on the material to produce thepads illustrated in Fig. 2;

Fig. 4 is a broken, enlarged view of a portion of the structureillustrated in Fig. 1.;

Fig. 5 is an enlarged broken sectional view of the structure illustratedin Fig. '4, taken on the lines 5-5 thereof;

Fig. 6 is a sectional view of the structure illustrated in Fig. 4, takenon the line 6--6 thereof, with the gathering device in lowered position;

Fig; 7 is a view of the structure illustrated in Fig'. 6with thegathering device in raised position;

Fig. 8 is an enlarged sectional view of the structure illustrated inFig. 6, taken on the line 8-8 thereof; I

Fig. 9 is a plan view of a fabric engaging and advancing foot employedon vthe machine;

practice Fig. 11 is a view of the end of one of the gathering devicesillustrated in Fig. 8;

Fig. 12 is a broken side view of the structure illustrated in Fig. 11;

Fig. 13 is a schematic diagram of the wiring connections employed in thedevice illustrated in Fig. 1; and,

Fig. 14 is an enlarged view in perspective of a pressure foot employedon the sewing machine illustrated in Fig. 2,

In Fig. 1, I have illustrated a series of elements embodying a machine Ifor distributing linters or other bers to a continuous sheet of materialI6 to form a pad thereon, which sheet and' pad passes throughcompression rolls I1 and onto a belt I9, which may sag between itssupports. By using the sagging belt, intermittent feed may be had fromthe belt to a stamping machine 2l. During the time the material isstopped after being advanced into the machine 2l, a die in the machinestamps out the pad and sheet simultaneously to predetermined size andshape. A conveyor 22, operated by the mechanism of the press 2lperiodically advances the stamped out units to position under agathering device 23 for the top cover material. 'I'he sheets of materialrest on a table 24 from which they are taken one at a time and placed onchannel-like elements 54 and the pad. 'Ihe arms of the forming device 23cooperate with the channel elements to gather the material along thelines to be sewn. After the material has been gathered in this manner,the pad and trim materials are advanced by the conveyor 22 to a positionabove continuously actuated conveyor chains 25 having projecting pinswhich pierce the backing sheet and pad when the conveyor 22 is loweredto dispose the assembled unit upon the conveyor chains 25. The conveyorchains 25 continuously advance the assembled units which are furtherengaged by feet 26 of a sewing machine 21. The stitching of the pads bythe machine occurs along the lines on which the gathering of the trimmaterial occurred.

The garnetting of fibers upon a continuously moving sheet of backingmaterial is illustrated and described in copending application of Clarfence W. Avery, Serial No. 58,859, filed January 13, 1936. and assignedto the assignee of the present invention. The intermittent feedingdevice I 9 is illustrated in combination with the press 2| in myco-pending application Serial No. 132,193, filed March 22, 1937, andwill not, therefore, be described herein in detail.

A shaft 3|, is carried by the press 2l and is driven in synchronism withthe gear elements which drive the belt I9, providing intermittentoperation to the conveyor 22 embodying a plurality of belts. Theopposite end oi' lthe belts Y pass over crown pulleys 32 a'nd idlercrown pulleys 33. disposed interjacent of the belt ends. The pulleys 32and 33 are mounted on shafts34 and 35 respectively, which are carried onarms 36 of bell crank levers 31. The bell crank levers are connected bylinks 38, to a piston 39, of the hydraulic cylinder 4I. 'Through theoperation of the piston within the cylinder, the bell cranks 31 areactuated about the pivots 42, to raise and lowerthe shafts 34 and 35,and, therefore, the pulleys 32 and 33 carried thereby. When the beltsare raised, the assembled material is lifted a suiiicient height abovethe pins 43 on the conveyor chains 25 to prevent engagementtherebetween. When the belts are lowered, the material is disposed uponthe pins 43 and the conveyor chain 25 driven at a constant speed by thesewingvmachine 21 moves the material from the belt and advances itthrough the sewing machine.

Referring to Fig.r3, I have illustrated the backing sheet I5 as having acontinuous pad 44 formed thereon as the sheet continuously advances.Periodically the material is advanced into the press 2| where a die,supported by the head 45 of the press, stamps the backing sheet l5 andpad 44 into predetermined shape, that is shown at 45 in the figure.After the head 45 is raised the stamped unit 46 is advanced onto theconveyor 22 and is advanced to the gathering device 23. During the timethe conveyor is at rest, that at least to permit a suiiicient length ofIthe backing sheet and pad to advance onto the conveyor I9, a sheet ofcovering material 41 is disposed upon the unit 45 and channel elements54. The sheets rest upon the table 24 from which they are moved one at atime, by an operator standing at each side of the machine, to within thejaws of the gathering device. Cover positioning elements 48 are disposedat'each side of the machine in which the corners of the material may begauged by the operator to accurately locate the material. Adjacent eachof the engaging elements, switches 49 are mounted in a position to beactuated by the fingers of the operator while holding the edges of thecorners of the cloth in position. The four switches are connected inseries as illustrated in Fig. 13 and must all be closed to operate thegathering device. This provides assurance that the hands of the operatorare out of contact with the device when actuated.

Two longitudinally adjustable elements are disposed at the sides of thedevice in which a pair of shafts 5I and 52 disposed laterally of thedevice are journaled for pivotal movements. The shaft 52 supports thelower jaws or channel ele--y ments 54 while the shaft 53 supports theupper jaws 55 which are of T-shape, as illustrated in Fig. 8. The shaft52 is provided with an arm 56 on one or both of its ends to which aspring 51 is connected to balance the weight of the lower jaws orelements 54. The channel elements 54 indent the padding material as itis advanced thereunder to cover receiving and gathering position. Thecover material 41 is stretched across the unit 48 and the switches 49actuated to operate a fluid valve which directs a flow of fluid to thecylinder 5B to actuate a piston rod 59 and link 5I secured to the end ofthe shaft 53. The fluid is delivered in the righthand end of `thecylinder as illustrated in Figs. 6 and '7 to draw the piston rodtherewithin to move the link 5I in a clockwise direction to rotate theupper jaws 55 downwardly onto the cover material. The material is drawnwithin the channel elements 54 disposed therebelow to provide fullnessthereto. It is to be understood that the formation of the paddingmaterial and the gathering of the cover material occurs along linesaligned with the sewing heads` of the multi-stitching machines. That isto say, the pad and cover material is preformed and provided with pleatfullness, respectively, along lines at which the stitching occurs. Uponthe release of the switches 49, fluid is directed into the opposite endof the cylinder 58 for moving the piston rod 59 outwardly to therebyrotate the shaft 53 along with the upper jaws 55 in a counter-clockwisedirection to a position illustrated in Fig. 7. Thereafter, the conveyor22 is raised and the assembled and formed unit is carried to positionover the continuously moving conveyor chains 25. At the end ofadvancement of the conveyor 22, the cylinder 4| is energized to actuatethe bell cranks 31 to lower the pulleys 32 and 33 and, therefore, theconveyor 22 to deposit the assembled unit upon the conveyor chains 25,'1'I'he pins 43 of the chains proa. ject through tlabacking material intothe padding material and advance the assembled unit vtoward the sewingmachine 21. Each time the shaft 3| is rot` d to advance the conveyor 22,the cylinder 4| s energized-to operate the bell cranks to raise thepulleys 32 and 33 to thereby raise the conveypr before it advances. Inthis `manner the bqking sheet and pad is continutached to each of theheads 3l are illustrated en iarged in Fig. 14. The feet comprise acasting i2 having an upwardly projecting portion 99 by which thecastings are secured to the sewing heads by suitaue means not hereillustrated in detail. A pair of sprockets 94 are journaled on a shaft(not shown) of the sewing machine 21, which shaft is journaled in thecasting 92. Sprocket wheels I5 are mounted at the front end of thecasting on shafts journaled in a bearing 83 which is adjustable by ascrew 91. I'he front end 69 of the als-ting is sloped upwardly toreceive the assembled material which is thereafter engaged by chains 59which are disposed on each side of the casting over the sprockets 34 and95 at opppsite ends thereof.

The outer surface of the links and plates of the chains are serrated at1I to prevent slippage from occurring between the chains and the engagedmaterial. The chains are guided in downwardly projecting slots in theside plates 12, the slack, return portion of the chains pass under theblocks 13 and 14 containing grooves which receive the chains. An opening15 isfprovided in the casting through which a needle 19 operatesV tostitch the material compressed and moved by the foot 26. The chains 25,as pointed out hereinabove, are driven from the sewing machine,

1 which driving occurs in timed relation with the operation ofthe,chains I9. 'Ihe chains 25 have the sprockets 33` thereof driven by acommon shaft 40, while the chain 59 has the sprocket 94 thereof driven4by a common shaft 19. T'he shafts 40 and 1l, are interconnected by apair of gears |00, which are similar, to have the shafts driven at aconstant speed. This produces the constant driving :relation betweenchains 25 and 59. The operation of both sets of chains in this mannermakescertain that the material moves through the sewing machine withoutthe elements thereof dipping relative to each other.

Outwardly of the sewing heads 6i and feet 26, a pair of'engaging andadvancing feet 11, similar to the'feetZB, are mounted directly over theouter conveyor chains 25. 'Ihe feet are iliustrated enlarged in Figs. 9and 10 and embody a casting 19 which is secured to a cross-bar 9I of themachine21 by a stud 92 by which the feet are adjusted in height relativeto the material. The shaftl of the sewing machine which drives thesprocket B4 of the foot 29 is also journaled in the casting 19 and alsodrives a sprocket 93 which is mounted on the foot 11. A sprocket chain94 is Vmounted over the sprocket wheel 93 and is guided in a channel 95in the bottom of the casting 19 which likewise slopes upwardly at itsfront endl. An adjustable sprocket 36 is mounted onthe front end of theshoe and i tensions the under portion of the chain, the slack or returnportion of the chain being encompassed by suitable guide plates 91 and98. The chain 94 is provided with a plurality of outwardly projecting,pins I9 which positively engage the cover material and pad above thepins in the chains 25 which engage the backing sheet and underportion ofthe pad. The feet 11 aid the youter chains 25 to advance the side edgesof the assembled material as the stitching occurs inter jacent thereof.

Through the use of the feet 29 and 11 in combination with the conveyorchains 25 assurance is had thatv the units advance uniformly through thesewing heads 6| without any shifting of the elements which make up theunits. Since the operation is continuous, the pads passing through themachine will be connected together byr threads which are united as themachine continues to operate until the next adjacent unit passesthereinto. As the units pass from the machine the threads joining thepads are cut and the operation is completed.

Referring to Figs. 11 and 12, I have illustrated the outer end of thegathering device 23 wherein the end of thev gathering jaw 55 has a.guide 9| associated therewith which is adjustable vertically relativethereto by a stud 92. A V-shaped body portion 93 is, provided on theadjusting device 9I which is dimensioned to be recessed within thechannel element 54 to thereby locate the lower edge of the blade 25 withthe bottom of the channel element. In this manner, the amount ofmaterial drawn into the channel element is regulated to thereby regulatethe size of the plait to be formed.

In Fig. 13, I have illustrated a wiring diagram wherein the plurality ofswitches 49 are illustrated in series relation with a circuit 94connected to a solenoid 95. The solenoid operates a fluid vvalve 99which controls the flow of fluid to and from the cylinder 59 whichoperates the gathering device. Since the two hands of each of theoperators must be employed for operating the switches, the arrangementprovides a safety factor preventing the hands of the operator from beingdisposed between the gatheringdevic when the device is movingdownwardly.

It will thus be seen that my method of constructing pads is continuous,embodying the feeding of a continuous sheet of backing materialuniformly across the conveyor of a "garnetting machine where a pad ofunwoven fiber material is disposed. After the pad is compressed throughrollers, it is intermittently fed while stamped into units ofpredetermined size and form which are further advanced intermittently tothe gathering device where a sheet of covering material is placedthereon and gathered along the lines to be sewn. The material is furtherintermittently advanced to a position over continuously operatingconveyor chains where it is disposed to -be uniformly advanced throughthe sewing machine. The various feed mechanisms are interconnected toprovide synchronized movements, and, except for the use of the operatorsfor placing the cover material upon the uni-ts, the operation isentirelyautomatic. The pads made in this manner are accurate of form,positively sewn and economicalof manufacture.

Formal changes may be made in the specific embodiment of the inventiondescribed. without departing from the spirit and substance of the broadinvention, the scope of which is commensurate with the appended claims.

l claim as my invention:

1. A method of constructing a pad embodying the steps, of continuouslyfeeding a backing sheet and padding material, of die stamping 'unitstherefrom, of applying a cover material to each' of the units, offorming fullness in said cover material,.and sewing the unit andmaterial along predetermined lines.

2i. A method of constructing a pad embodying `the steps, of continuouslyfeeding a backing sheet and padding material, of cutting unitstherefrom, of applying a cover material to each of the units, and sewingthe assembled material along predetermined lines.

3. A method of constructing a pad embodying the steps, of continuouslyfeeding` a backing sheet and padding material, of intermittently feedingsaid sheet and material, of severing portions therefrom, ofintermittently advancing said severed portions, of disposing coveringmaterial on said severed portions, and continuously feeding saidassembled materials through a machine to secure the materials togetherat predetermined points.

. djA method of constructing a pad embodying V ing sheet, of applying acovermaterial to said unit, of forming fullness in said material alongpredetermined lines, and sewing said material and unit together alongsaid lines.A

` 6. A method of constructing a pad embodying the steps of severing aunit from a pad and backing sheet, of applying a cover material to saidunit, of depressing said pad along predetermined lines, of gatheringsaid material to provide fullness along said lines, and stitching saidmaterial andv unit'together along said lines.

7. A method of constructing a pad embodying 'the steps of continuouslyfeeding a backing sheet and padding material, of stamping units ofpredetermined form therefrom, of depressing said padding material ofsaid units along predetermined lines, of applying a cover material toeach of the units, of forming fullness in said cover `material, andsewing the units and material along said lines.

8. A pad forming device including, in combina- I tion, means forcontinuously feeding a backing sheet, means for continuously forming apad thereon as the sheet is advanced, a die intermittently receivingsaid sheet and pad for stamping units therefrom, means for gatheringfullness in a cover material disposed on said units and means forstitching said-units and material together.

9. A pad forming device including, in combination, means forcontinuously feeding a backing sheet, means for continuously forming apad thereon as the sheet is advanced, means for intermittently advancingsaid sheet' and pad, a die for blanking out a unit after eachadvancement, meansfor intermittently advancing said unit to depress thepad along predetermined lines, a cover material, means for gatheringfullness in said cover material after it isfdisposed on said unit, andmeans 'for stitching said material and unit together. f

10. A pad forming device including, in combination',` means foradvancing a backing sheet having a pad thereon,means for stamping outunits from said pad and backing sheet, means for gathering fullness in acover material and means for stitching said material and unit together.

11. A pad forming device including, in combination, means for 'advancinga backing sheet having a pad thereon, means for stamping out units fromsaid pad andv backing sheet, means for'gathering fullness in a covermaterial after it is disposed on said unit, conveyor chains foradvancing said assembled elements, a sewing machine, and pressure' meansfor compacting said elements and feeding the elements through saidmachine. l"

, 12. A pad forming device including, in combination, a sewing machinehaving a plurality Vof spaced heads, a bed, conveyor chains on said bed,one disposed between each of said heads, and pressure feet havingconveyor chains thereon disposed above said bed, each supportedindividually on one of said heads.

v13. A pad forming device including, in combination, a'sewing machinehaving a plurality of spaced heads, a bed, conveyor chains on said beddisposed between said heads onA each 'side ofthe outermost heads, apressure foot supported Vindividually on each of said heads above said'bed between said chains, said pressure feet'having conveyor chainsthereon.

14. A pad forming device including, in combination, a sewing machinehaving a plurality of spaced heads, a bed, conveyor chains on said beddisposed lbetween said heads on each side of the outermost heads, apressure foot supported individually on each of said heads above saidbed between said chains, said pressure feet having conveyor chainsthereon, and means for driving all of said chains in timed relation.

' l5. A pad forming device including, in combination, a conveyor forintermittently advancing a plurality of superposed elements forming aunit to be stitched, a continuously moving conveyor overlapping saidfirst conveyor, means for relatively raising and lowering said conveyorsto permit the intermittent advancementof said unit out of engagementwith said second conveyor and for thereafter disposing said unit uponsaid second conveyor, a sewing machine, and means for continuouslyadvancing said second conveyor through said sewing machine.

16. A pad forming device including, incombination, a conveyor forintermittently advancing a plurality'of superposed elements forming aunit to be stitched, a continuously' moving conveyor overlapping saidrst conveyor, means for relatively raising and lowering said conveyorsto permit the' intermittent 'advancement of said unit y out ofengagement with said second conveyor and for thereafter disposing saidunit upon said sec- V0nd conveyor, ya sewing machine, heads on saidmachine disposed between the elements ofsaid second conveyor andpressure feet on-said heads cooperating with said elementsfor movingsaid unit through said machine. L

- ALFRED H. HABERSTUMI.

